Lattice Support Structures

ABSTRACT

The present disclosure is drawn to a lattice support structure, comprising a plurality of fiber-based cross supports intersecting one another to form a multi-layered node. The multi-layered node can be consolidated within a rigid mold in the presence of resin, heat, and pressure. In another embodiment, a lattice support structure can comprise a first cross support comprising fiber material; a second cross support comprising a fiber material, said second cross support intersecting the first cross support; and multi-layered nodes located where the first cross support intersects the second cross support. The multi-layered nodes can comprise at least two layers of the first cross support separated by a least one layer of the second cross support. Also, one of the first cross support or the second cross support can be curved from node to node.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/692,879, filed Dec. 3, 2012 which is acontinuation application claiming the benefit of U.S. patent applicationSer. No. 12/542,442, filed Aug. 17, 2009, entitled, “LATTICE SUPPORTSTRUCTURES,” which claims the benefit of U.S. Provisional PatentApplication No. 61/089,124,” filed on Aug. 15, 2008, entitled,“THREE-DIMENSIONAL GEO-STRUT STRUCTURE AND METHOD OF MANUFACTURE, eachof which are incorporated in their entirety by reference and made a parthereof.

BACKGROUND

Structural supports, including lattice-type structural supports, havebeen developed for many applications which provide high strengthperformances, but benefit from the presence of less material. In otherwords, efficient structural supports can possess high strength, and atthe same time, be low in weight resulting in high strength/weightratios. Truss systems have been pursued for many years and continue tobe studied and redesigned by engineers with incremental improvements.

In the field of carbon fiber lattice support structures, a primary issueconcerning such systems relates to the construction of joints, couplingmembers of the system together forming a single larger unit. Approachesto coupling the lattice members such as weaving, twisting, mechanicalfastening, bypassing of nodes, or the like, have provided marginalresults regarding strength performances of the resulting structures.Thus, it would be desirable to provide a lattice support structure thathas exceptional node strength and a high level of structural integrityusing fiber-based materials.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional features and advantages of the invention will be apparentfrom the detailed description which follows, taken in conjunction withthe accompanying drawings, which together illustrate, by way of example,features of the invention; and, wherein:

FIGS. 1A-1C depict exemplary embodiments of lattice support structuresin accordance with embodiments of the present disclosure;

FIGS. 2A-2C depict alternative exemplary embodiments of lattice supportstructures in accordance with embodiments of the present disclosure;

FIGS. 3A-3C depict alternative exemplary embodiments of lattice supportstructures in accordance with embodiments of the present disclosure;

FIGS. 4A-4C depict alternative exemplary embodiments of lattice supportstructures in accordance with embodiments of the present disclosure;

FIG. 5 depicts an alternative exemplary embodiment of another latticesupport structure in accordance with embodiments of the presentdisclosure;

FIGS. 6A-6F depict various arrangements of cross supports and variousnode configurations in accordance with embodiments of the presentdisclosure;

FIG. 7 depicts a multi-layered node configuration prior to fusion and/orconsolidation in accordance with embodiments of the present disclosure,where each cross support includes multiple layers and the layers arestacked with other cross support material from different cross supportstherebetween;

FIG. 8 depicts node layering in cross section in accordance with oneembodiment of the present disclosure;

FIG. 9 depicts node layering in cross section in accordance with anotherembodiment of the present disclosure;

FIG. 10, depicts a cutaway portion of an exemplary consolidated node inaccordance with embodiments of the present disclosure; and

FIG. 11 depicts an exemplary consolidated node sectioned orthogonally tothe longitudinal axis depicting the change in member width approachingthe node and massing of layered material near and on the node.

Reference will now be made to the exemplary embodiments illustrated, andspecific language will be used herein to describe the same. It willnevertheless be understood that no limitation of the scope of theinvention is thereby intended.

DETAILED DESCRIPTION

The following detailed description of representative embodiments of thepresent disclosure makes reference to the accompanying drawings, whichform a part hereof and in which are shown, by way of illustration,various representative embodiments in which the teachings of thedisclosure can be practiced. While these embodiments are described insufficient detail to enable those skilled in the art to practice thedisclosure, it should be understood that other embodiments can berealized and that various changes can be made to the disclosure withoutdeparting from the spirit and scope of the present invention. As such,the following detailed description is not intended to limit the scope ofthe disclosure as it is claimed, but rather is presented for purposes ofillustration, to describe the features and characteristics of thepresent disclosure, and to sufficiently enable one skilled in the art topractice the disclosure. Accordingly, the scope of the present inventionis to be defined by the appended claims.

In accordance with this, a lattice support structure can comprise aplurality of fiber-based cross supports intersecting one another to forma multi-layered node. The multi-layered node can be consolidated withina groove of a rigid mold in the presence of resin, heat, and pressure.In one embodiment, the cross supports can have a thickness where themulti-layered node is thinner than the sum of the thickness of eachcross support at the multi-layered node.

In another embodiment, a lattice support structure can comprise a firstcross support comprising fiber material, and a second cross supportcomprising a fiber material, where the second cross support intersectsthe first cross support. The lattice support structure can also includemulti-layered nodes located where the first cross support intersects thesecond cross support. The multi-layered nodes can comprise at least twolayers of the first cross support separated by a least one layer of thesecond cross support. Additionally, at least one of the first crosssupport or the second cross support can be curved from node to node.

It is noted that when referring to a “multi-layered” node, what is meantis that the cross supports are not merely stacked on top of one another,but rather, a first individual cross support has multiple layers withone or more layer(s) of material from other cross supports therebetween.Thus, in order to be “multi-layered, there must be at least one crosssupport or layer of at least one cross support that is between at leasttwo layers of another cross support. Typically, however, each crosssupport of the node is layered with other cross support layerstherebetween (as shown hereinafter in FIG. 7).

It is also notable that the present disclosure provides lattice supportstructures or fiber-based composite articles. Examples of specificmethods for the fabrication thereof and related systems, as well assolid mandrels used to form such structures, can be found in Applicants'copending U.S. patent applications filed Aug. 17, 2009 under AttorneyDocket Nos. 3095-003.NP, 3095-004.NP, and 3095-006.NP, each of which isincorporated herein by reference in its entirety.

In further detail with respect to embodiments of the present disclosure,several figures provided herein setting forth additional features of thelattice support structures of the present disclosure are provided.

With specific reference to FIGS. 1A, 1B, and 1C, one embodiment of alattice support structure is shown. FIG. 1A and FIG. 1C are identical,showing different views of the same structure. FIG. 1B is identical toFIG. 1A, except that it does not include optional support collars 20 oneach end of the lattice support structure. These lattice supportstructures each comprise a plurality of fiber-based cross supportsintersecting one another to form several multi-layered nodes 22. It isnoted that there are eight longitudinal cross supports 24 and eighthelical cross supports 26 a, 26 b (four twisting clockwise 26 a from topto bottom and four twisting counterclockwise 26 b from top to bottom).Nodes are formed in this embodiment where three cross supports (onelongitudinal cross support, one clockwise helical cross support, and onecounterclockwise helical cross support) intersect. The helical crosssupports form curved node-to-node cross support segments. This structurealso demonstrates 4 helical cross supports taken at a 1 turn per 7inches pitch, with 4 counter wrapped helical cross supports of equalpitch combined with longitudinal cross supports, coupled at a pluralityof multi-layered nodes where the ends have been consolidated by acollar. It is noted that this structure profile, including number anddirection of turns, number and position of various cross supports, etc.,is merely exemplary, and can be modified slightly or significantly inaccordance with embodiments of the present disclosure.

With specific reference to FIGS. 2A, 2B, and 2C, another embodiment of alattice support structure is shown. FIG. 2A and FIG. 2C are identical,showing different views of the same structure. FIG. 2B is identical toFIG. 2A, except that it does not include optional support collars 20 oneach end of the lattice support structure. These lattice supportstructures each comprise a plurality of fiber-based cross supportsintersecting one another to form several multi-layered nodes 22. It isnoted that there are eight longitudinal cross supports 24 and eighthelical cross supports 26 a, 26 b (four twisting clockwise 26 a from topto bottom and four twisting counterclockwise 26 b from top to bottom).Nodes are formed in this embodiment where three cross supports (onelongitudinal cross support, one clockwise helical cross support, and onecounterclockwise helical cross support) intersect. The helical crosssupports form curved node-to-node cross support segments. It is notedthat the primary difference between the structures shown in FIGS. 1A-1Cand the structures shown in FIGS. 2A-2C is the increased frequency oftwists for the helical lattice support structures in FIGS. 2A-2C. Thisstructure also demonstrates 4 helical cross supports taken at a 5 turnsper 7 inches pitch, with 4 counter wrapped helical cross supports ofequal pitch combined with longitudinal cross supports, coupled at aplurality of multi-layered nodes where the ends have been consolidatedby a collar.

With specific reference to FIGS. 3A, 3B, and 3C, another embodiment of alattice support structure is shown. FIG. 3A and FIG. 3C are identical,showing different views of the same structure. FIG. 3B is identical toFIG. 3A, except that it does not include optional support collars 20 oneach end of the lattice support structure. These lattice supportstructures each comprise a plurality of fiber-based cross supportsintersecting one another to form several multi-layered nodes 22 a, 22 b.Again, it is noted that there are eight longitudinal cross supports 24.However, in this embodiment, there are sixteen (16) helical crosssupports 26 a, 26 b (eight twisting clockwise 26 a from top to bottomand eight twisting counterclockwise 26 b from top to bottom). Also, inthis embodiment, two different types of multi-layered nodes are formed.First, multi-layered nodes 22 a are formed where three cross supports(one longitudinal cross support, one clockwise helical cross support,and one counterclockwise helical cross support) intersect. Multi-layerednodes 22 b are also formed where two helical cross supports (oneclockwise helical and one counterclockwise helical) intersect without alongitudinal cross support. This structure also demonstrates 8 helicalcross supports taken at a 2 turns per 7 inches pitch, with 8 counterwrapped helical cross supports of equal pitch combined with longitudinalcross supports, coupled at a plurality of multi-layered nodes where theends have been consolidated by a collar. It is also noted thatadditional multi-layered nodes are present that do not includelongitudinal cross supports.

With specific reference to FIGS. 4A, 4B, and 4C, another embodiment of alattice support structure is shown. FIG. 4A and FIG. 4C are identical,showing different views of the same structure. FIG. 4B is identical toFIG. 4A, except that it does not include optional support collars 20 oneach end of the lattice support structure. These lattice supportstructures each comprise a plurality of fiber-based cross supportsintersecting one another to form several multi-layered nodes 22. In thisembodiment, there are no longitudinal cross supports. Also in thisembodiment, there are twelve (12) helical cross supports 26 a, 26 b(four twisting clockwise 26 a from top to bottom and eight twistingcounterclockwise 26 b from top to bottom). This embodiment thus alsodemonstrates the ability to design for unidirectional torsion and otherloads through varying the number of members in the clockwise directionfrom those in the counterclockwise direction. Nodes 22 are formed wheretwo helical cross supports (one clockwise helical cross support and onecounterclockwise helical cross support) intersect without a longitudinalcross support.

With specific reference to FIG. 5, another embodiment of a latticesupport structure is shown. In this FIG., not only are longitudinalcross supports 24 and helical cross supports 26 shown, butcircumferential cross supports 28 are also shown. Again, these latticesupport structures each comprise a plurality of fiber-based crosssupports intersecting one another to form several multi-layered nodes 22a, 22 b, 22 c. In this embodiment, there are eight helical crosssupports and eight longitudinal cross supports, as described previouslyin FIGS. 1A-1C. However, there are also two additional circumferentialcross supports. Thus, in this embodiment, there are three differentmulti-layered node configurations. First, multi-layered nodes 22 a areformed where four cross supports (one longitudinal cross support, onecircumferential cross support, one clockwise helical cross support fromtop to bottom, and one counterclockwise helical cross support from topto bottom) intersect. Multi-layered nodes 22 b are also formed wherethree cross supports (one longitudinal cross support, one clockwisehelical cross support from top to bottom, and one counterclockwisehelical cross support from top to bottom) intersect. Next, multi-layerednodes 22 c are formed where two cross supports (one longitudinal crosssupport and one circumferential cross support) intersect.

It is noted that FIGS. 1A to FIG. 5 are provided for exemplary purposesonly, as many other structures can also be formed in accordance withembodiments of the present disclosure. For example, twist pitch can bemodified for helical cross supports, longitudinal cross supports addedsymmetrically or asymmetrically, circumferential cross supports can beadded uniformly or asymmetrically, node locations and/or number of crosssupports can be varied, as can the overall geometry of the resultingpart including diameter, length and the body-axis path to includeconstant, linear and non-linear resulting shapes as well as the radialpath to create circular, triangular, square and other polyhedralcross-sectional shapes with or without standard rounding and filletingof the corners, etc. In other words, these lattice supports structuresare very modifiable, and can be tailored to a specific need. Forexample, if the weight of a lattice support structure needs to bereduced, then cross lattice support structures can be removed atlocations that will not experience as great of a load. Likewise, crosslattice support structures can be added where load is expected to begreater.

In accordance with this, FIGS. 6A-6F provide exemplary relativearrangements for helical, longitudinal, and circumferential crosssupports that can be used in forming lattice support structures. Variousnode placements are also shown in these FIGS. FIG. 6A depicts alongitudinal cross support 24 and helical cross supports 26, forming amulti-layered node 22 at the intersection of all three cross supports.This is similar to that shown in FIGS. 1A-3C and 5. FIG. 6B depicts alongitudinal cross support 24, helical cross supports 26, and acircumferential cross support 28 forming a multi-layered node 22 at theintersection of all four cross supports. FIG. 6C depicts a longitudinalcross support 24, helical cross supports 26, and a circumferential crosssupport 28 forming three different types of multi-layered nodes 22 a, 22b, 22 c. FIG. 6D depicts a longitudinal cross support 24 and helicalcross supports 26 forming two different types of multi-layered nodes 22a, 22 b. FIG. 6E depicts a longitudinal cross support 24, helical crosssupports 26, and a circumferential cross support 28 forming threedifferent types of multi-layered nodes 22 a, 22 b, 22 c. It is notedthat this arrangement provides two multi-layered nodes that are similarto FIG. 6C (22 a, 22 b) and one that is different (22 c). Specifically,multi-layered node 22 c in FIG. 6C comprises a circumferential crosssupport and a helical cross support, whereas multi-layered node 22 c inFIG. 6E comprises a longitudinal cross support and a helical crosssupport, thus illustrating the flexibility of design of the latticesupport structures of the present disclosure. FIG. 6F depicts alongitudinal cross support 24, helical cross supports 26, and acircumferential cross support 28 forming four different types ofmulti-layered nodes 22 a, 22 b, 22 c, 22 d.

Turning to FIG. 7, more detail is provided with respect to formingmulti-layered nodes in accordance with embodiments of the presentdisclosure. Specifically, for illustrative purposes only, themulti-layered node 22 shown in FIG. 6A is shown in more detail prior toheat and pressure fusion or consolidation. As can be seen in thisembodiment, a longitudinal cross support 24 and two helical crosssupports 26 are shown. Specifically, each cross support comprisesmultiple layers, and at the multi-layered node, each layer is separatedfrom a previously applied layer by at least one other cross supportlayer. In this manner, a multi-layered node is formed that can be curedin accordance with embodiment of the present disclosure.

With specific reference to curing, in one embodiment, the curing processcomprises applying 90-150 psi nitrogen gas at 250-350° F. for a soakperiod of about 10 to 240 minutes depending on the size of the part andits coinciding tooling. In this embodiment, the cross supports withlayered and interleaved nodes can be applied to a solid mandrel andwrapped with a membrane or bag. Once in place, the pressure from theambient curing gas provides an even press through the bag on the entirepart, thus curing and consolidating the multi-layered nodes.

FIGS. 8 and 9 depict schematic representations of possible multi-layerednode structures. Specifically, FIG. 8 depicts layering using towmaterial of low fiber count and what a nodal cross-section might appearto be like before consolidation and FIG. 9 depicts what the layeringwould appear like after consolidation. It is noted that the fiber ofhigh fiber-count tow or tape products may appear like FIG. 9 prior toconsolidation as well, and after consolidation, the node would appeareven more flattened in shape. In these FIGS., it is assumed that sixlayers of tow or tape are wrapped to demonstrate the leaving of layersin the nodes. In each of these two figures, the cross supports shown onend (along the Z-axis) in cross-section 30 can be assumed to be memberswhich continue into and out of the respective FIG. The cross supportmaterial 32 intersecting them (along the X- and Y-axis) represent asingle cross-support members, and collectively, these cross supportsform nodes of the shape similar to 22 b, 22 c and 22 d in FIGS. 6E and6F. In these illustrations, the helical cross support is approachingfrom the left side. Were there to be an additional helical memberwrapped in the opposite direction, it would look to be the mirror imageof the one shown and approach from the right side of the figures.

FIG. 10 sets forth a cutaway cross-section of a multi-layered node aftercuring and consolidation of the layered material. Note thecross-sectional area of the member is set into a half-pipe geometry 34(as consolidated and forced in half-pipe shaped grooves from a solidmandrel), though other geometries are certainly a design option,depending on the shape of the solid mandrel grooves. This consolidatednode structure shows a distinction in structure compared to the priorart junctions where weaving and/or braiding are used. Most notably, abuild-up of material in the node resulting from coupling the materialfrom various members in various directions allows for the forming of aconsolidated node that is compacted and cured, adding strength to theoverall structure. Rather than stacking each layer directly on top ofthe next, the leaving as in FIGS. 8 and 9 allows for individual wraps 36of tow or tape to end up side-by-side and stacked as a function of thegeometry they are forced into before curing. Likewise, FIG. 11 setsforth an exemplary consolidated node sectioned orthogonally to thelongitudinal axis depicting the change in member width approaching thenode and massing of layered material near and on the node as justdescribed.

In further detail with respect to the embodiments shown in FIGS. 1-11,the present disclosure relates to helical cross supports wrapped arounda centerline where the helical cross supports have curved segmentsrigidly connected end to end and layered with or without axial, radial,or laterally configured lattice support structures (e.g., longitudinaland/or circumferential cross supports) which can be straight or curvedend to end. The curves of the helical cross support segments can complydirectly with the desired geometric shape of the overall unit. In oneembodiment, the structure can include at least two helical crosssupports. As described above, at least one of the helical cross supportswraps around the centerline in one direction (clockwise from top tobottom, for example) while at least one other wraps around in theopposite direction (counterclockwise from top to bottom, for example).Though a “top to bottom” orientation is described, this is done forconvenience only, as these structures may be oriented other than in avertical configuration (horizontal, angular, etc.). Helical crosssupports wrapped in the same direction can have the same angularorientation and pitch, or can have different angular orientations andpitch. Also, the spacing of the multiple helical cross supports may notnecessarily spaced apart at equal distances, though they are oftenspaced at equal distances. The reverse helical cross supports can besimilarly arranged but with an opposing angular direction. These helicalcross supports can cross at multi-layered nodes, coupling counteroriented helical cross supports through layering of the filaments. Thiscoupling provides a ready distribution of the load onto the variousstructural supports. When viewed from centerline, the curving segmentsof the components can appear to match the desired geometry of thestructural unit with no significant protrusions, i.e. a cylindrical unitappears as a circle from the centerline. In this embodiment, allcomponents can share a common centerline.

Additional structural supports can also be included in the latticesupport structure. Components which are straight from junction tojunction may be included to intersect multi-layered nodes parallel tothe centerline to form unidirectional members (e.g. longitudinal crosssupports). Components, which can be curved or straight, can also beadded circumferentially to intersect with the multi-layered nodes alongthe length of the lattice support structure. These circumferential crosssupports can be added to increase internal strength of the structure.These additional members may be added to intersect at the multi-layerednodes, but do not necessarily need to intersect the nodes formed by thehelical cross supports crossing one another, e.g. they may cross atareas between helical-helical nodes. In other words, the longitudinalcross supports and/or the circumferential cross supports may form commonmulti-layered nodes with helical-helical formed multi-layered nodes, orcan form their own multi-layered nodes between the helical-helicalformed multi-layered nodes. In either case, the multi-layered nodes canstill be formed using filament layering. The count of helical memberscompared to other members is flexible in certain embodiment to allow formulti-layered nodes to occur only as lattice support structuresintersect in a given location, or to allow for multiple node locationscomposed of two or more, but not all of the members in the structure.The capability of such a design allows versatility in the number ofhelical cross supports, the coil density, as well as the number ofmulti-layered nodes or intersections with axial, radial, or lateralcomponents. As a general principle, the more strength desired for anapplication, the higher the coil density; whereas, the less strengthdesired, the fewer coils and wider the wrap length per coil may bepresent.

Structural supports may be covered with a material to create theappearance of a solid structure, protect the member or its contents, orprovide for fluid dynamic properties. The current disclosure istherefore not necessarily a traditional pipe, rope, coil, spring, orsolid shaft, neither is it a reinforcement for a skin cover. Even thoughthe structures disclosed herein are relatively lightweight, because ofits relative strength to weight ratio, these lattice support structuresare strong enough to act as stand-alone structural units. Further, thesestructures can be built without brackets to join individual latticesupport structures.

In accordance with one embodiment, the present disclosure can provide alattice structure where individual supports structures are wrapped withuni-directional tow, where each helical cross support, for example, is acontinual strand. Further, it is notable that an entire structure can bewrapped with a single strand, though this is not required. Also, thelattice support structures are not weaved or braided, but rather, can bewrapped layer by layer where a leaving structure is created in thenodes. Thus, where the helical cross supports intersect one anotherand/or one or more longitudinal and/or circumferential cross supports,these intersections create multi-layered nodes of compounded materialwhich couple the members together. In one embodiment, the compositestrand does not change major direction at these multi-layered nodes toform any polyhedral shape when viewed from the axial direction. FIG. 11as a cross section of a longitudinal member depicts the bending of thehelical members intended in this disclosure. This is also evident inFIGS. 1-5 through the creation of cylindrical parts using thistechnology. Thus, the strand maintains their path in its own axial,circumferential, or helical direction based on the geometry of the part.Once wrapped in this manner, the multi-layered nodes and the entire partcan be cured and/or fused as described herein or by other methods, andthe multi-layered nodes can be consolidated

It is also noted that these lattice support structures can be formedusing a solid mandrel, having grooves embedded therein for receivingfilament when forming the lattice supports structure. Being produced ona mandrel allows the cross supports of the structural unit to be round,triangular or square or any sectional form of these including but notlimited to rounding one or more corners. For production, the filamentsare wrapped around a break-away mandrel generally conforming to thedesired patterns of the members and providing a solid geometric base forthe structure during production. Though a secondary wrap, e.g., KEVLAR,may be applied once the structure has been cured or combined with theprimary fibers before cure, consolidation of members can be achievedthrough covering the uncured structure with a bagging system, creatingnegative pressure over at least the multi-layered nodes, and running itthrough an autoclave or similar curing cycle. This adds strength throughallowing segments of components to be formed from a continuous filament,while also allowing the various strands in a single member to beconsolidated during curing.

Turning now to more specific detail regarding consolidation of themulti-layered nodes, it has been recognized that the closer the fibersare held together, the more they act in unison as a single piece ratherthan a group of fibers. In composites, resin can facilitate holding thefibers in close proximity of each other both in the segments of thecross supports themselves, and at the multi-layered nodes when more thanone directional path is being taken by groups of unidirectional fibersare layered. In filament winding systems of the present disclosure,composite tow or tape (or other shaped filaments) can be wound andshaped using a solid mandrel, and then the composite fibers forcedtogether using pressure. Under this pressure, heat can be used to fusethe multi-layered nodes, generating a tightly consolidated multi-layerednode. Thus, the multi-layered node is held in place tightly usingpressure, and under pressure, the multi-layered node (including thefilament or tow material and the resin) can be heat fused or cured,making the multi-layered node more highly compacted and consolidatedthan other systems in the prior art. Further, by using a rigid mandrelwith specifically cut paths for the unidirectional fiber to be laidinto, the multi-layered nodes are held tight during the consolidationprocess. Industry-standard bags, polyurea-based products, or otherbagging materials placed over the fibers can act as a pressure medium,pushing the fibers into the grooves of the solid mandrel and removingany voids which may occur by other methods. As a result, high levels ofconsolidation (90-100% or even 98-100%) can be achieved. In other words,porosity of the consolidated material providing voids and weak spots inthe structure are significantly reduced or even virtually eliminated. Inshort, consolidation control using a rigid mandrel, pressure over thewound filament or fibers, and resin/heat curing provides high levels ofconsolidation that strengthen the lattice as a whole.

In addition, there are other advantages of the system described herein,namely the ability to manipulate the cross-sectional geometry of thecross sectional shape of the individual cross supports. As a function ofthe solid mandrel and the silicone, VacuSpray 20, or other similarmaterials, forcing the fibers into the cut grooves allows for thegeometry of the cross supports to be modified in cross section. Anygeometry which can be applied to the grooves of the rigid mandrel can beused to shape resulting cross supports and can range fromsquare/rectangular to triangular, half-pipe, or even more creativeshapes such as T-shape cross sections. This provides the ability tocontrol or manipulate the moment of inertia of the cross supportmembers. For example, the difference in inertial moments of a flat unitof about 0.005″ thickness and a T-shaped unit of the same amount ofmaterial can reach up to and beyond a factor of 200. With the use of asolid mandrel, pressure application, and resin/temperature curing,measurement has shown that geometric tolerances can be kept at less than0.5%.

The above detailed description describes the disclosure with referenceto specific representative embodiments. However, it will be appreciatedthat various modifications and changes can be made without departingfrom the scope of the present disclosure as set forth in the appendedclaims. The detailed description and accompanying drawings are to beregarded as merely illustrative, rather than as restrictive, and allsuch modifications or changes, if any, are intended to fall within thescope of the present disclosure as described and set forth herein. Morespecifically, while illustrative representative embodiments of theinvention have been described herein, the present invention is notlimited to these embodiments, but includes any and all embodimentshaving modifications, omissions, combinations (e.g., of aspects acrossvarious embodiments), adaptations and/or alterations as would beappreciated by those in the art based on the foregoing detaileddescription. The limitations in the claims are to be interpreted broadlybased on the language employed in the claims and not limited to examplesdescribed in the foregoing detailed description or during theprosecution of the application, which examples are to be construed asnon-exclusive. Also, any steps recited in any method or process claimscan be executed in any order and are not limited to the order presentedin the claims.

1. A lattice support structure, comprising a plurality of fiber-basedcross supports intersecting one another to form a multi-layered node,said multi-layered node being consolidated within a groove of a rigidmold in the presence of resin, heat, and pressure, wherein saidmulti-layered node comprises at least two layers of the cross supports.2. The lattice support structure of claim 1, wherein each of said crosssupports have a thickness, and wherein said multi-layered node isthinner than the sum of the thickness of each cross support at themulti-layered node.
 3. The lattice support structure of claim 1, whereinthe multi-layered node comprises multiple layers of all of the crosssupports intersecting to form the node.
 4. The lattice support structureof claim 1, further comprising a plurality of multi-layered nodes, eachmulti-layered node formed from a plurality of fiber-based cross supportsintersecting one another, at least one of said cross supports beinglayered at each of the plurality of multi-layered nodes.
 5. The latticesupport structure of claim 4, wherein the at least one cross support iscurved between two multi-layered nodes.
 6. The lattice support structureof claim 4, said lattice support structure having a generallycylindrical shape, and comprising at least one helical cross support. 7.The lattice support structure of claim 6, further comprising a secondhelical cross support.
 8. The lattice support structure of claim 7,wherein the helical cross support intersects the second helical crosssupport to form the multi-layered node.
 9. The lattice support structureof claim 8, wherein the helical cross support intersects the secondhelical cross support to form a plurality of multi-layered nodes. 10.The lattice support structure of claim 6, further comprising alongitudinal cross support that intersects the helical cross support toform the multi-layered node.
 11. The lattice support structure of claim10, wherein the longitudinal cross support intersects the helical crosssupport to form a plurality of multi-layered nodes.
 12. The latticesupport structure of claim 6, further comprising a circumferential crosssupport that intersects the helical cross support to form themulti-layered node.
 13. The lattice support structure of claim 1,wherein at least three cross supports intersect at the multi-layerednode.
 14. The lattice support structure of claim 13, wherein at leastthree cross supports each include at least two layers at themulti-layered node.
 15. The lattice support structure of claim 1,wherein the multi-layered node has increased surface area along a topsurface of the lattice support structure compared to a bottom surface ofthe lattice support structure.
 16. The lattice support structure ofclaim 1, wherein the fiber material includes carbon fiber.
 17. Thelattice support structure of claim 1, wherein the fiber materialincludes fiber glass.
 18. (canceled)
 19. The lattice support structureof claim 1, wherein the fiber material is composited with a resin. 20.The lattice support structure of claim 1, wherein the rigid mold is agrooved mandrel.
 21. A lattice support structure, comprising: a) a firstcross support comprising fiber material; b) a second cross supportcomprising a fiber material, said second cross support intersecting thefirst cross support; and c) multi-layered nodes located where the firstcross support intersects the second cross support, said multi-layerednodes comprising at least two layers of the first cross supportseparated by at least one layer of the second cross support, wherein atleast one of said first cross support or said second cross support iscurved from node to node. 22-45. (canceled)